Baffle constructs for insulative fill materials

ABSTRACT

The inventive subject matter is directed to an assembly of a plurality of baffle constructs which each include: a primary baffle, comprising a pliable textile, and a secondary baffle. The baffle constructs are configured to be alignable along a vertical axis relative to the ground. Each primary baffle defines a bounded, volumetric space for enclosing a first volume of insulative fill material and a secondary baffle. Each secondary baffle defines a bounded, volumetric space for enclosing a second volume of fill material. One or more of the secondary baffle are disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the first insulative material when the primary baffle is maintained in an intended vertical orientation. The secondary baffles are mainly responsible for filling the primary baffle to its intended shape in an upper portion of the primary baffle.

BACKGROUND

The inventive subject matter is generally directed to textile constructs that provide thermal insulation in consumer products. Products like jackets and other garments often have a multi-layered construction made up of an assembly of fabrics and insulation materials. One common construct for colder climates is an assembly of baffles. For example, baffles may be provided between the two outer-most layers of a garment to create chambers that hold insulative fill material, such as natural or synthetic down.

Gravity and use can cause fill material to settle, compact or compress at the bottom of a baffle, creating voids at the top portion of a baffle. Because of this, conventional baffles have a limited height that helps prevent settling and compression of fill material. In other words, as the columnar height of fill material increases, so does its weight and compressive force. Hence, because of the increased weight, there is more pronounced compression and settling of the fill material in taller baffles. In such cases, the voiding of material at the top of the baffle flattens, indents, or depresses the upper portion of the baffle.

These kinds of changes in the baffle are problematic for at least two reasons: (1) the flattened areas cause cold spots in the panel of baffles, and (2) the flattened areas are unsightly and do not provide the intended aesthetic of plump, uniformly filled baffles.

Typically, baffles have a height of a height of less than 15 cm in garments such as a jacket. Disadvantageously, relatively short baffles require more seams or joints between baffles over a given area. The seams or joints result in potential cold spots. Having many seams or joints also restricts the aesthetics of a panel of baffles and does not free the designer to reduce the number of seams or joints for a cleaner or less busy appearance to the baffle panel.

In short, conventional baffles have the foregoing and other disadvantages, and there is a need for improved baffle constructions that allow for uniform fill distribution, elimination of cold spots, reduction in seams or other joints, and/or greater design flexibility, for example.

SUMMARY

The inventive subject matter generally relates to baffle constructs for use in consumer products, such as garments and sleeping bags. In certain aspects, the inventive subject matter provides an innovative solution to the problem of settling and compacting of fill material, which limits the height of baffles and consequently baffle performance and aesthetics.

In one possible embodiment, the inventive subject matter is directed to an assembly of a plurality of baffle constructs. Each baffle construct includes: a primary baffle, comprising a pliable textile, and one or more secondary baffles, which may also comprise a pliable textile. The baffle constructs are configured to be alignable along a vertical axis relative to the ground. Each primary baffle defines a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space. Each secondary baffle defines a bounded, volumetric space for enclosing a second volume of fill material. One or more of the secondary baffle are disposed in the primary baffle so that most (i.e., more than 50%) of the second volume of insulative fill material of the secondary baffle(s) is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation. In other words, the secondary baffle or baffles are mainly responsible for filling the primary baffle to its intended shape in an upper portion of the primary baffle.

In the foregoing and other embodiments, the primary baffle has a bottom and a secondary baffle has a bottom, the bottom of the secondary baffle being spaced a predetermined height above the bottom of the primary baffle.

In the foregoing and other embodiments, the primary baffle may have a predetermined profile in a desired expanded condition and the secondary baffle has a predetermined desired profile in the expanded condition, and wherein the primary baffle's profile in the expanded condition is supported and not disrupted by the secondary baffle when the secondary baffle's profile in the expanded condition.

In the foregoing and other embodiments, the primary baffle may have a height H and the secondary baffle has a height H′ and the ratio H/H′ is at least 1.25.

In the foregoing and other embodiments, the primary baffle may have a height H and a secondary baffle has a height H′ and the ratio H/H′ is between 1.25 and 10.

In the foregoing and other embodiments, a single secondary baffle may be enclosed in the primary baffle and an upper end of the secondary baffle is pendulously appended to an upper end of the primary baffle.

In the foregoing and other embodiments, the secondary baffle may have an oblong shaped configuration.

In the foregoing and other embodiments, may have the secondary baffle has a fully pendulous configuration.

In the foregoing and other embodiments, the secondary baffle may have a generally teardrop or piriform shape.

In the foregoing and other embodiments, the assembly may have a face layer and a back layer, and the primary baffles are defined in part by horizontal seam or joints connecting the face layer and back layer and which define a top and the bottom for a given baffle.

In the foregoing and other embodiments, the secondary baffle(s) may be disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer is free of any seams or joints for the secondary baffle(s).

In the foregoing and other embodiments, the primary baffle in an expanded condition may have sides that converge at upper and lower ends when moving from an intermediate section.

In the foregoing and other embodiments, an upper-most secondary baffle(s) may have a first edge of the secondary baffle that merges into the upper end of a primary baffle, and a second edge is downwardly spaced apart from the upper edge and merges into a vertical wall of the primary baffle, such that the secondary baffle's bounded space is defined in part by a wall of the primary baffle.

In the foregoing and other embodiments, a second secondary baffle may be spaced, at least in part, below the upper-most secondary baffle, a first edge of the secondary baffle merges into the vertical wall of the primary baffle, and a second edge is downwardly spaced apart from the second secondary baffle's upper edge and merges into the vertical wall of the primary baffle, such that the second secondary baffle's bounded space is defined in part by a wall of the primary baffle.

In the foregoing and other embodiments, when the secondary baffle(s) is/are in an expanded condition, the primary baffle in an expanded profile may receive fill material below the bottom of the secondary baffle(s) and along at least one vertical side of the secondary baffle(s).

In the foregoing and other embodiments, at least two secondary baffles may be disposed in the primary baffle and arranged at different heights in the primary baffle.

In the foregoing and other embodiments, at least three secondary baffles may be disposed in the primary baffle and arranged at different heights in the primary baffle.

In the foregoing and other embodiments, the secondary baffles may stack in partial overlap with the lower one of the secondary baffles.

In another possible embodiment, the inventive subject matter is directed to a garment having a panel configured to cover a torso area of a wearer. The panel includes an assembly of a plurality of baffle constructs. Each baffle construct includes a primary baffle consisting of a pliable textile, and one or more secondary baffles. The baffle constructs are configured to be alignable along a vertical axis relative to the ground. Each primary baffle defines a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space. Each secondary baffle defines a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation.

In the foregoing and other embodiments, an insulative fill material may be disposed in each primary baffle and secondary baffle, the insulative fill material filling the primary baffle and secondary baffles to a desired profile.

In another possible embodiment, the inventive subject matter is directed to a method of producing an insulative panel. The method includes the steps of: providing an assembly of a plurality of baffle constructs, each baffle construct including a primary baffle, consisting of a pliable textile, and one or more secondary baffles. The baffle constructs are configured to be alignable along a vertical axis relative to the ground. Each primary baffle defines a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space. Each secondary baffle defines a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above the height of most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation; and filling each primary baffle and secondary baffle with an insulative fill material to a desired profile.

The foregoing is not intended to be an exhaustive list of embodiments and features of the inventive subject matter. Persons skilled in the art can appreciate other embodiments and features from the following detailed description in conjunction with the drawings. These and other embodiments are described in more detail in the following detailed descriptions and the figures.

The following is a description of various inventive lines under the inventive subject matter. The appended claims, as originally filed in this document, or as subsequently amended, are hereby incorporated into this Summary section as if written directly in.

BRIEF DESCRIPTION OF THE DRAWINGS

The appended figures show embodiments according to the inventive subject matter, unless noted as showing prior art.

FIG. 1 shows a side, cross-section of an individual baffle.

FIG. 2A shows a side, cross-section of an assembly of baffles like the baffle of FIG. 1.

FIG. 2B shows a perspective view of the assembly of FIG. 2 from a face layer.

FIG. 2C shows a perspective view of the assembly of FIG. 2 from a face layer.

FIG. 4 shows a side, cross-section of a first alternative embodiment an individual baffle.

FIG. 5 shows a side, cross-section of a second alternative embodiment an individual baffle.

FIG. 6 shows a side, cross-section of a third alternative embodiment an individual baffle.

FIG. 7 shows a garment incorporating panels of baffles according to one of the foregoing embodiments or any other embodiment contemplated herein.

FIG. 8 shows a side, cross-section of an alternative embodiment of an individual baffle.

DETAILED DESCRIPTION

Representative embodiments according to the inventive subject matter are shown in FIGS. 1-8, wherein the same or generally similar features share common reference numerals.

The inventive subject matter generally relates to baffle constructs for use in consumer products, such as garments and sleeping bags. In certain aspects, baffles are arranged as a panel of a plurality of primary baffles 10, each primary baffle has a selected theoretical profile when in an expanded condition that defines an enclosed main volumetric space for holding fill material. Each primary baffle has one or more secondary baffles, e.g., baffles 12, 112, 212, 312, 412 each with an enclosed secondary baffle volumetric space, disposed within the primary baffle's enclosed main volumetric space. A secondary baffle is disposed at at least a top portion of a primary baffle's volumetric space. The void of the main volumetric space and the void for the secondary baffle each receive fill material. Because the secondary baffle's volumetric space is disposed at the top portion of the main volumetric space, the fill material in the secondary baffle is suspended above the lower void of the main volumetric space and does not compress the fill material below it. Consequently, the main volumetric space does deflate, compact or flatten out when used. The secondary baffles serve to keep the top portion of the primary baffles in a plumped, inflated, or expanded state. Thereby, the primary baffle may be better presented and maintained according to its theoretical profile or other desired expanded state.

Advantageously, the inventive subject matter allows for apparel and other products with a panel of baffles to have vertically taller baffles and to prevent the down or other fill material from migrating to the bottom of the baffle. To maintain loft in the baffle, the innovative baffle constructs include an internal or secondary baffle that does not create any indentations or depressions in the surrounding primary baffle, thus creating a taller, more continuously plumped or expanded primary baffle.

The baffle constructs can be formed into a predetermined assembly of multiple baffles. For example, they can be assembled as a plurality of adjacent, consecutive baffles forming a flat panel. Other constructions are possible too. For example, the baffles can be arranged to overlap or nest in multiple layers.

As used herein, the term “panel” means there is a section that generally extends over at least one plane. For example, in the case of garments, a panel may extend over some or all the front abdomen of a wearer. A panel may extend over multiple planes. For example, in the case of garments, the panel may extend over and from the front abdomen over the other sides of the wearer's body. The panel may extend partly or fully over one or both sides of the wearer. It may extend from one or both sides partly or fully over the back of the wearer.

FIGS. 1-8 show baffle 10 for holding a fill material, typically an insulative fill material of discrete particles, such as natural down. The baffles may be used in a variety of products, including garments, sleeping bags, sleeping pads, footwear uppers, gloves, headwear, pillows, cushions, beds, bed toppings, and other such objects. However, the baffle constructs are particularly suited for use in panels that have a vertical orientation (height) relative to the ground, i.e., an orientation wherein there is a column of fill material that is acted on by gravity. The inventive subject may benefit not only garments and other products that are primarily oriented vertically in use but also products that are primarily oriented horizontally in use. For example, sleeping bags or comforters may be hung and stored vertically, so the inventive subject matter may benefit such products.

In some embodiments, the baffle constructs have a height of at least 5 cm, 8 cm, 11 cm, 12 cm, 13 cm, 14 cm, 15 cm, 16 cm, 17 cm, 18 cm, 19 cm, 20 cm, 25 cm, 30 cm, 35 cm, 40 cm, 45 cm, 50 cm, or thereabout any such number, for supporting a column of fill material.

Looking at one possible embodiment, FIGS. 2A-2C show a panel 1 formed from an assembly of a plurality of baffle constructs. Each baffle construct consists of a primary baffle 10 and one or more secondary baffles 12 contained within the primary baffles. The baffle constructs are configured to be alignable along a vertical axis relative to the ground. For example, they would stack vertically when integrated into a garment and when the garment is worn as intended, as seen in FIG. 7, for example.

Each primary baffle defines a bounded, volumetric space 11, i.e, a compartment, for enclosing: (1) a first volume of insulative fill material 2 in a first part 11 a of the space, and (2) a secondary baffle 12 in a second part 11 b of the space.

Each secondary baffle defines the bounded, volumetric space (11 b) and is a compartment for enclosing a second volume of fill material 3. The secondary baffle is disposed in the primary baffle so that the second volume of insulative fill material is contained above the height of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation. This keeps the second volume of material from settling to a lower portion of the main space 11. Thereby, the fullness of the upper portion may be maintained under conditions that would otherwise result in settling or compaction of the fill material. As discussed below, the upper portion can be maintained in a desired degree of fullness, resistant to settling by a single, appropriately-sized secondary baffle, or by a series of secondary baffles that are arranged in the part of the primary baffle that is susceptible to deflation or flattening.

In embodiments for which naturally down is the intended fill material, the height of each stacking compartment for holding fill material is equal to or less than 15.24 cm, otherwise the down may unacceptably settle and compact, producing substantial dead space at the top of the compartment. Under the inventive subject matter, the foregoing height may be referred to herein as the “maximum stacking height” of down or another fill material. For other fill materials like Thermoball™ insulation, the maximum stacking height may be less than 6.35 cm, or less than 15.24 cm, or less than 30.48 cm, depending on how high the material can be stacked without unacceptable compacting. Unacceptable compacting occurs where the material after a period of reasonable intended use has primary baffles that perceptibly lose their intended overall form.

Accordingly, prior art baffles are limited to a maximum stacking height, if they are to maintain substantial fullness when oriented vertically. However, the inventive subject matter is not so limited. By using stackable compartments, a primary baffle may be formed that has a height that is multiples of the maximum stacking height.

Looking at the embodiment of FIGS. 1-2C as generally representative, the primary baffle 10 has a height H between a bottom 14 and top 21. The secondary baffle has a height H′ between bottom 16 and top 19. The bottom of the secondary baffle 12 is spaced a predetermined height H″ 14 above the bottom of the primary baffle. The intermediate space between the bottoms may therefore be filled with fill material 2. The height H′ of the intermediate space may represent the height to which a fill material is naturally resistant to settling and compaction, e.g., the maximum stacking height. The height H′ from the bottom of the secondary baffle to its top may also represent such a height. Accordingly, the sum total columnar height of fill material 2 in the intermediate space, and fill material 3 in the secondary baffle, is more than what would resist settling and compaction normally, if there was no suspension of fill material by secondary baffle 14. However, by dividing the main space 11 into a main compartment and a sub-compartment via the secondary baffle, the main compartment holds its full height in fill material, with the bottom of the secondary baffle serving to suspend the fill material and divide the total height into sub-compartments that individually provide non-settling or compacting columns of fill material. Notably, the stacking heights of each sub-compartment may be about the same if the same fill material is used in space 11 a (volume not occupied by secondary baffle 12) and the space 11 b of the secondary baffle 13.

In other embodiments, the void at the bottom of the main baffle and a series of stacking, secondary baffles may effectively allow for a total stacking of fill material to a height that is a multiple of the maximum stacking height for fill material used. For example, FIG. 4 shows a primary baffle 10 with three vertically stacking secondary baffles 112 a, 112 b, 112 c. While the height of each stacking secondary baffle does not necessarily have to be limited to a maximum stacking height for a fill material, if each were configured to such a height, the primary baffle 10 could have a height that is about three times the maximum stacking height of the fill material, adding the height of each secondary baffle, and factoring in that there is some minor overlapping of secondary baffles, and there is an intermediate space between the bottom of the primary baffle and the bottom of the lowermost secondary baffle 112 c.

In some embodiments, the primary baffle has a height H and the secondary baffle has a height H′ and the ratio H/H′ is at least 1.25. In some embodiments, the primary baffle has a height H and a secondary baffle has a height H′ and the ratio H/H′ is between 1.25 and 5.

As seen in Figures, the primary baffle has a predetermined profile in a desired expanded condition, and the secondary baffle has a predetermined desired profile in the expanded condition. The primary baffle has an oblong profile in the illustrated examples, but other profiles are also contemplated. The secondary baffle also has an oblong profile in the illustrated examples, but other profiles are also contemplated.

The secondary baffle, or combination of secondary baffles, may be expanded with fill material so that it generally follows or complements the predetermined profile of the primary baffle in its predetermined expanded profile. In other words, the secondary baffle 12 or baffles in the main compartment of a primary baffle 10 are configured to expand to a profile that supports and maintains the fullness of the predetermined profile of the main baffle when space 11 a is filled with fill material.

In any of the embodiments disclosed herein, the secondary baffle can be connected to an inner surface of the primary baffle in a variety of ways. The Figures show a few different possibilities. For example, FIGS. 1-4 and 6 show a “J” connection where a top edge 18 of secondary baffle 12 is connected to the top, inner surface 20 of the primary baffle 10 at or about the upper apex or end 21 of the primary baffle. The edge connects to the inner surface at a joint 19, which may coincide with apex or top 21. The secondary baffle 12 has a vertically oriented wall 22 that extends downwardly from the top edge 18. The wall runs generally parallel to the opposing vertical walls 24, 26 of the primary baffle. The wall 22 terminates in a bottom edge 28 that connects to vertical wall 24. Accordingly, wall 22 is expandable or displaceable from the wall 24, providing an intermediate space for fill material. Similarly, wall 22 spaces apart from wall 26 as fill material is added, and fill material may be disposed in the space between the walls.

Although the edge 18 is shown connecting at the top 20 of the primary baffle, in other embodiments, it could connect into vertical wall 24 of the primary baffle. For example, as seen for example in the case of secondary baffles 112 b and 112 c in FIG. 4.

In the embodiment shown, wall 22 may be made of a sheet material that has a length that is greater than the distance between joint 19 and a joint 29 where bottom edge 28 joins vertical wall 24. By using a drapable sheet material for the wall, a pendulous portion 30 of secondary baffle 12 is created, which hangs downwardly below where joint 29 is disposed on wall 24. The pendulous portion has opposing sides 32, 34 that are vertically oriented and not connected to wall 24. The pendulous section's bottom is the bottom 16 of the secondary baffle. In this example, the inner surface of secondary baffle 12 is defined in part by primary baffle's wall 24 and the inner surface of wall 22 (both the vertical and bottom, horizontal portions). In FIG. 4, a series of secondary baffles 112 a, 112 b, and 112 c may be vertically arranged along wall 24. The secondary baffles may partially overlap.

From the foregoing discussion, when secondary baffle(s) and are in an expanded condition, the remaining space of the primary baffle can hold fill material below the bottom of the secondary baffle(s) and along at least one vertical side (e.g., wall 22) of the secondary baffle(s).

A secondary baffle can have a fully pendulous configuration. A fully pendulous configuration is one where the vertically oriented sidewalls of the secondary baffle are free from the walls of the primary baffle so that the secondary baffle is suspended just from a top connection. An example of a fully pendulous configuration is seen in FIG. 5. In secondary baffle 212 the opposing edges of a sheet wall material connect to or near the top of the primary baffle 10. The portion of the sheet material in between the edges hangs downwardly and forms the closed bottom 16 of the secondary baffle. In other words, the sheet material hangs in a generally U-shaped form. Fill material in the primary baffle can surround the vertical sides 32, 34 and bottom side 16 of the secondary baffle 212.

In other embodiments, the secondary baffle can have a non-pendulous form where the bottom 16 does not hang below joint 29. For example, FIG. 8 shows primary baffle 10 with a secondary baffle 412 in a C-shaped form that has bottom 16 coinciding with joint 29. This form of baffle is relatively shorter than a pendulous one and may be suited for use at the top of a primary baffle, as seen in FIG. 8.

In other embodiments, the primary baffle's main space can include not only a first secondary baffle 312 a in an upper portion but also a second secondary baffle 312 b in a lower portion, as seen in FIG. 6. The two secondary baffles collectively have a configuration that mirrors the primary baffle and is concentrically disposed within the primary baffle. Accordingly, based on the teachings herein, the main compartment of the primary baffle can be subdivided into any number of sub-compartments via secondary baffles, from 1, 2, 3, 4, 6 or more sub-compartments are possible. The arrangement of baffles collectively mimics the shape of the primary baffle such that they sufficiently maintain its intended profile when sufficiently filled with fill material. The secondary baffles may do this without a need for the primary baffle to have fill material other than what is provided in the secondary baffle(s), as seen in the case of FIG. 6.

In any embodiment, the cross-sectional profile of the main and secondary baffles, taken across a vertical orientation may vary. (In all cases, baffles are assumed to be in an expanded condition representing the desired profile). Typically, they will have an oblong profile, namely a height that is greater than width, using major axes. The height to width ratio may be 1.2:1, 1.5:1, 2:1, 2.5:1, 3:1; 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, or higher. In the Figures, primary baffle 10 has an elliptical profile. And the secondary baffles of FIGS. 1-5 generally resemble a tear drop or piriform shape, with walls that diverge going from a top end toward a rounded bottom. Another way to characterize some of the many possible profiles that a primary or secondary baffle may have is that the profile converges at upper and lower ends when moving from an intermediate section of maximum width. Possible profiles under this description include, ellipse, oval, tear drop, piriform, and circle.

The baffle constructs contemplated under the inventive subject matter can be assembled into a panel. The baffles may all have the same configuration or they may have a mix of configurations. The inventive panels can be used in any application in which conventional baffles are used.

In one possible assembly of baffles, the primary baffles are defined in part by horizontal seams or joints 19 connecting a panel's face layer 36 and back layer 38 and which define a top and the bottom for a given baffle 10. In some embodiments, the back layer 38 is the same as vertical wall 24, and the face layer 36 is the same as vertical wall 26.

Advantageously, by disposing all the secondary baffles on and vertically spaced along the same inner surface 24 of the back layer 38, free from the face layer 36, the face layer is free of any seams or other joints for the sub baffle(s). This is seen in FIGS. 1-7 which show the face layer 36 of panel 1 having just joints 19, free of any seems or other joints for the secondary baffles contained within the primary baffles. For example, looking at back layer 38 in FIG. 2C, seams 19 for the primary baffles are visible; seams 29 for secondary baffles 12 are also visible. In contrast, FIG. 2B shows face layer 36 on the opposite side of back layer 38. Only seams 19 are visible because secondary baffles 12 are all aligned on wall 24 (back layer 38 in this case), and all the secondary baffles are disconnected from the wall 26 (face layer 36 in this case).

As generally shown in FIG. 7, any panel contemplated herein may be used as a portion of a garment 4, such as an upper body covering or lower body covering. Panels can cover a wearer's torso, in whole or part, including chest areas, stomach areas, shoulder areas, upper back areas, lower back areas. Panels can be included in the pelvic region and/or leg regions of garments and cover various areas of those regions.

The baffles constructs may be formed of separate pieces of woven or nonwoven textiles or fabrics, which are joined together. The baffles could also be formed of non-textiles that have textile properties and are suitable for use in garments and other applications contemplated herein, e.g., drapable or pliable thin sheets, webs, films, and membranes of material, such as plastic or elastomeric materials. Joints where one section of material merges into another section can be seams formed by stitching, adhesives, thermal bonding or fusion. The joints can also be based on seamless weaving or knitting, and other known or hereafter discovered joining techniques.

The inventive baffle constructs contemplated herein may be in whole or part a unitary woven or nonwoven article with different sides, sections, or layers seamlessly joined. In other words, all portions are formed, for example, in the same weaving or knitting process, and are not separate panels that are joined together after each section is woven or knit. For instance, baffle panels having a unitary woven construction are disclosed in U.S. Publ. No. US20170172240, which is hereby incorporated by reference in its entirety for all it discloses.

As indicated above, panel 1 has a multilayer construction for the primary baffles of a first or face layer 36 and a back layer 38. The labeling of layers 36, 38 is arbitrary, as either may be deemed one or the other. The labeling will have significance in the context of end products or components for end products: (i) the face layer normally faces outwardly towards the environment, and (ii) the back layer faces inwardly against a substrate, e.g., in the case of a jacket or sleeping bag, the face layer faces away from the user's body and the back layer faces the user's body. The panels with baffle constructs may also have intermediate layers of baffle constructs to form multi-layer panels, such as shown in U.S. Publ. No. US20170172240.

The layers may have the same or different compositions of yarns or other woven filament. The face layer 36 may be selected to provide desired performance and/or aesthetic attributes. For example, it may be a lightweight material such as taffeta. Or it may be a durable or wear resistant material, such as 40D polyester or ripstop nylon; a weather resistant material that blocks water or wind; an elastic material; or a material that provides a combination of such attributes. The face can be woven in various Dobby patterns.

The back layer 38 may be a comfort material, such as a taffeta; a material that wicks moisture; or a material that provides a combination of such attributes. An interlayer (not shown) may be the same or different from the other layers, or a combination of materials used in the other layers. The face and/or can have finishes such as DWR for water repellency or CIRE to make the fabric downproof and less air permeable.

In one representative, non-limiting example, face layer 36 has a woven construction such as Dobby, jacquard, etc., to produce a desired weave type (e.g., ripstop, twill, etc.), while the back layer 38 may have a basic taffeta construction. The interlayer 14 may also have a basic taffeta construction like the back layer. Alternatively, it may be like the face layer (e.g., ripstop, twill, etc.).

Various conventional materials with known attributes may be selected to provide desired attributes, such as those listed above, including nylon, polyester, polypropylene, rayon, elastane, silk, cotton, wool, acetate, acrylic, aramid, hemp, jute, lyocell, cashmere, triexta, polyethylene, rayon, and blends of the foregoing, and all recycled versions of any of the foregoing or blends of the foregoing. Deniers for the layers may be 5D or higher, and any layer may be a blend of deniers. For example, deniers of 10D, 15D, 20D, 30D, 40D, 50D, 60D, 70D, 75D, 80D, 90D, 100D, 120D, 140D, 150D, 160D, 180D, or 200D for typical sleeping bag and apparel applications, and a ripstop construction, or other known or discovered Dobby patterns, may be used with any layer to impart additional tear resistance and strength.

A given layer may also have varying attributes in different zones, and there may be transition zones between different zones that allow for a progressive change in attributes, as disclosed in more detail below.

FIGS. 1-7 show a theoretical or desired shape of the baffles when each is filled properly. However, as persons in the art will appreciate, in the field baffle shapes can vary from a desired shape as a result of use, and the theoretical or desired shape is a general representation of a desired condition, which is obtainable by person skilled in the art using the teachings herein.

Each baffle 10 in the illustrated examples has a generally oval-like or elliptical-like cross-sectional profile, following a longitudinal axis of the multi-layer fabric construct. In other embodiments, baffles may have other volumetric shapes like triangles, pentagons, hexagons, or other polygons, circles and other shapes defining a bounded area. Because of their drapable, pliable, fabric nature, the baffles may have some variation in shape if the baffles are incompletely filled or are filled with, for example, clumpy material that does not uniformly distribute within a baffle. Taking the structures shown in the Figures, the variation can be from flattened, with no filling in the baffles, to round with overstuffing of the baffles. The theoretical shape of the baffles is generally the volumetric shape that the baffle construct would take in the intermediate shape between flat and overstuffed to a round shape (in the case of the baffles shown). In the case of baffles structured in other shapes, e.g., polygons, as the baffle expands from an expected intermediate shape generally representing or recognizable as a polygon, the corners will curve creating a rounder shape. Another way to view the theoretical shape is to imagine an array of the baffles to be made of an inelastic, air impermeable fabric that was inflated with air until it just reached tautness. This should be the oval-like structure shown. In the following discussion, references to baffle shapes and geometries assume that baffle construct is in its theoretical expanded state unless indicated otherwise.

Each baffle 10, 12, 112, 212, 312, 412 in a vertical orientation, extends latitudinally (widthwise) through the construct as a hollow compartment for receiving a fill material 2, 3. The width of a baffle typically is as least 10 cm, 15 cm, 20 cm 25 cm, 30 cm, 35 cm, 40 cm, 50, cm, 75 cm, 100 cm, 150 cm, or 200 cm.

The baffles may also have rectilinear forms that approximate an oval or ellipsis such as a rhombus or rhomboidal form. The Figures show representative geometries for primary baffles consistent with the foregoing description. However, the inventive subject matter is not limited to oval-like or elliptical-like geometries. It also contemplates, for example, any version of a trapezoid up to a rectangle and down to a triangle may be used and substituted in for the oval-like baffles shown in the Figures. And, as noted, shapes representing any desired bounded area may be used in certain embodiments.

In each baffle construct, the baffles may be woven to have varying configurations, i.e., size, shape, or volume, based on differences in the length, height, cross-section, or volume of a baffle. One advantage of varying baffle parameters is that the construct can be tuned for performance needs. For example, for a parka, higher volume baffles could be positioned at a user's chest where more insulation may be desirable. Lower volume baffles could be positioned at a user's arms or underarms, where less insulation is needed, allowing for more mobility. Lower volume baffles may be positioned at joint areas where more flexibility is needed. Baffles configured with fabrics allowing for more weatherproofness (water and/or wind) or breathability can also be mapped to body zones. For example, the baffles mapping to a user's underarm area may be made of layers of fabric that are more porous and breathable.

FIG. 7 shows a representative product, namely a parka, which may incorporate a baffle construction shown in the Figures or otherwise disclosed and contemplated herein. The baffles according to the inventive subject matter may be incorporated partially or fully through such end products.

Once the baffle is formed, a fill material 2, 3 may be placed in the baffle compartments. First, openings at one side of baffle construct are closed using known means. For example, the openings can be closed by stitching along one selvedge edge of the baffle construct. This is just one representative, non-limiting approach for a closure. For example, in addition to stitching, the baffle ends may be woven closed.

Loose fill material, such as natural or synthetic down may be blown in using known techniques for filling baffles. In general, a blowing system includes a supply of fill material, one or more tubes from the blowing system are placed in in openings on the unsealed side of the baffle construct. The fill material is then blown into the compartments to partially or fully fill the compartments. Alternatively, synthetic, non-blown insulative material may be placed into the baffles. After the fill material is supplied, the unsealed side of the baffle construct may be sealed by stitching, or other known means.

After filling and sealing, the baffle construct may be assembled with other materials to make a finished end-product or component thereof. Additional layers of material may be added to the baffle construct. For example, a layer of durable or wear resistant material may be added. A layer of waterproof/breathable material may be added. A comfort liner may be added. The baffle construct may be used as a shoe upper and a sole or sole component may be added.

The loose fill contemplated for use with the baffle constructs disclosed and contemplated herein may be any natural fill material such as down or feathers, vegetable or animal fibers or fur, or combinations of the foregoing. One example of synthetic down is Thermoball™ (available in products from The North Face®, a division of VF Outdoor, Inc., Alameda, Calif., USA), which is based on round fiber clusters from Primaloft™, Inc., Latham, N.Y., USA. The insulative may also consist of synthetic/down blends, general synthetics, foam, or any other insulate material know or discovered insulative material suitable for use in baffles for apparel, sleeping bags and other end products contemplated herein.

Fill power (or the equivalent for synthetic insulation) may be any desired range from 100, 200, 300, 400, 500, 550, 600, 650, 700, 750, 800, 850, 900, or more, or any range in between based on any generally accepted industry protocol for determining fill power.

In some applications, a baffle construct may have varying thread densities across layers or zones. For example, in many applications, the only layers that need to be completely downproof are the outer layers. An interlayer or secondary baffle fabric, only needs to be dense enough to hold the majority of the down in place (i.e., if some feathers transfer from baffle to baffle, it is generally not an issue). Removing density from the interlayer allows for higher density in the outer layers and reduction of the overall weight of the construct. Accordingly, in this example, the reduction of density in the interlayer is for weight saving purposes, not for the downproof purpose described above. As a weight saving measure, it is contemplated that the interlayer can be a low-density taffeta or a lattice-like structure like an open mesh.

The foregoing approaches of selectively varying yarn denier, yarn material (e.g., hydrophobic, hydrophilic, elastic, etc.), or fabric density may be used in other applications. For example, the foregoing principles may be used to provide selective breathability, windproofness, waterproofness, thermal insulation, moisture transport, elasticity, abrasion resistance, cut/tear resistance, anti-compression resistance, increased compressibility, purely aesthetic features, such as color amongst others, and other desired attributes in one layer or zone versus another.

In addition to the foregoing approaches for providing downproofness, independent or supplemental approaches include external finishing techniques such as a cire finishes, coatings, and/or laminates.

One standard for assessing downproofness has been set by the International Down and Feather Laboratory Institute (IDFL), and may be found on their website www.idfl.com, with a current test at http://www.idfl.com/media/pdfs/IDFL%20Downproof%20vs%20Air%20Permeability.pdf.

Under the 2008 test at the above link, downproofness is the fabric's ability to contain down and feathers. The test involves placing a test pillow into a tumbling box where it is tumbled for 30 minutes, during which time it is struck by rubber stoppers (complete procedure is available upon request). This procedure attempts to mimic the actual use of the product. Downproofness is considered poor when many fibers and/or feathers can pass through the fabric.

The rating is based on a scale from 1-5 (with 1 being the worst and 5 being the best). The rating is based on the number of fibers and/or feathers that pass through the fabric of a test pillow.

Rating System:

5=Pass (little or no leakage through fabric)

4=Pass (minimal or normal leakage through fabric)

3=Borderline

2=Fail (above average leakage through fabric)

1=Extreme Fail (significant leakage through fabric)

Another standard for evaluating the suitability of a fabric to contain fill material is fiberproofness. This is an analogous evaluation to downproofness but applies to synthetic fiber fills. A fiberproof fabric may be slightly more air permeable than downproof but still prevents the migration of synthetic insulations like basic Primaloft insulation.

As used herein, “and/or” means “and” or “or”, as well as “and” and “or.” Moreover, all patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes. The principles described above in connection with any particular example can be combined with the principles described in connection with any one or more of the other examples. Accordingly, this detailed description shall not be construed in a limiting sense, and following a review of this disclosure, those of ordinary skill in the art will appreciate the wide variety of fluid heat exchange systems that can be devised using the various concepts described herein. Moreover, those of ordinary skill in the art will appreciate that the exemplary embodiments disclosed herein can be adapted to various configurations without departing from the disclosed principles.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the disclosed innovations. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of this disclosure. Thus, the disclosed inventions are not intended to be limited to the embodiments shown herein, but are to be accorded the full scope consistent with the language of this disclosure, wherein reference to an element in the singular, such as by use of the article “a” or “an” is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the elements of the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No element is to be construed under the provisions of 35 USC 112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or “step for”.

Thus, in view of the many possible embodiments to which the disclosed principles can be applied, it should be recognized that the above-described embodiments are only examples and should not be taken as limiting in scope. All rights to claim the subject matter disclosed herein are reserved, including the right to claim any and all combinations of subject matter described herein, including but not limited to all that comes within the scope and spirit of the following claims. 

1. An assembly of a plurality of baffle constructs, each baffle construct comprising: a primary baffle, comprising a pliable textile, and one or more secondary baffles, the baffle constructs configured to be alignable along a vertical axis relative to the ground; each primary baffle defining a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space; and each secondary baffle defining a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation.
 2. The assembly of claim 1 wherein the primary baffle has a bottom and the secondary baffle has a bottom, the bottom of the secondary baffle being spaced a predetermined height above the bottom of the primary baffle.
 3. The assembly of claim 1 wherein the primary baffle has a predetermined profile in a desired expanded condition and the secondary baffle has a predetermined desired profile in the expanded condition, and wherein the primary baffle's profile in the expanded condition is supported and not disrupted by the secondary baffle when the secondary baffle's profile in the expanded condition.
 4. The assembly of claim 1 wherein the primary baffle has a height H and the secondary baffle has a height H′ and the ratio H/H′ is at least 1.25.
 5. The assembly of claim 1 wherein the primary baffle has a height H and a secondary baffle has a height H′ and the ratio H/H′ is between 1.25 and
 10. 6. The assembly of claim 5 wherein a single secondary baffle is enclosed in the primary baffle and an upper end of the secondary baffle is pendulously appended to an upper end of the primary baffle.
 7. The assembly of claim 1 wherein the secondary baffle has an oblong shaped configuration.
 8. The assembly of claim 1 wherein the secondary baffle has a pendulous configuration.
 9. The assembly of claim 8 wherein the secondary baffle has a generally teardrop or piriform shape.
 10. The assembly of claim 1 wherein the assembly has face layer and a back layer and the primary baffles are defined in part by horizontal seam or joints connecting the face layer and back layer and which define a top and the bottom for a given baffle.
 11. The assembly of claim 10 wherein the secondary baffle(s) is/are disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer is free of any seams or joints for the secondary baffle(s).
 12. The assembly of claim 10 wherein each secondary baffle has a pendulous profile.
 13. The assembly of claim 1 wherein the primary baffle in an expanded condition has sides that converge at upper and lower ends when moving from an intermediate section.
 14. The assembly of claim 1 wherein an upper-most secondary baffle(s) has a first edge of the secondary baffle merges into the upper end of a primary baffle, and a second edge is downwardly spaced apart from the upper edge and merges into a vertical wall of the primary baffle, such that the secondary baffle's bounded space is defined in part by a wall of the primary baffle.
 15. The assembly of claim 14 further comprising a second secondary baffle spaced at least in part below the upper-most secondary baffle, a first edge of the secondary baffle merges into the vertical wall of the primary baffle, and a second edge is downwardly spaced apart from the second secondary baffle's upper edge and merges into the vertical wall of the primary baffle, such that the second secondary baffle's bounded space is defined in part by a wall of the primary baffle.
 16. The assembly of claim 7 wherein the secondary baffle(s) has/have a pendulous profile.
 17. The assembly of claim 7 wherein the secondary baffle(s) is/are disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer does not show any seams or joints for the secondary baffles, the wall with which the second edge of the secondary baffle merges with being the back layer.
 18. The assembly of claim 1 wherein when the secondary baffle(s) and is/are in an expanded condition, the primary baffle in an expanded profile can receive fill material below the bottom of the secondary baffle(s) and along at least one vertical side of the secondary baffle(s).
 19. The assembly of claim 10 wherein at least two secondary baffles are disposed in the primary baffle and are arranged at different heights in the primary baffle.
 20. The assembly of claim 1 wherein at least three secondary baffles are disposed in the primary baffle and are arranged at different heights in the primary baffle.
 21. The assembly of claim 19 wherein the secondary baffles are each disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer is free of any seams or joints for the secondary baffles.
 22. The assembly of claim 19 wherein one of the secondary baffles stacks in partial overlap with the lower one of the secondary baffles.
 23. A garment comprising, a panel configured to cover a torso area of a wearer, the panel comprising: an assembly of a plurality of baffle constructs, each baffle construct comprising: a primary baffle, comprising a pliable textile, and one or more secondary baffles, the baffle constructs configured to be alignable along a vertical axis relative to the ground; each primary baffle defining a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space; and each secondary baffle defining a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation.
 24. The garment of claim 23 further comprising an insulative fill material disposed in each primary baffle and secondary baffle, the insulative fill material filling the primary baffle and secondary baffles to a desired profile.
 25. A method of producing an insulative panel, comprising: providing an assembly of a plurality of baffle constructs, each baffle construct comprising: a primary baffle, comprising a pliable textile, and one or more secondary baffles, the baffle constructs configured to be alignable along a vertical axis relative to the ground; each primary baffle defining a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space; and each secondary baffle defining a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation; and filling each primary baffle and secondary baffle with an insulative fill material to a desired profile. 